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This is actually my first attempt at mandalorian armor. I'm going to do a relatively standard set of armor, but with my own few twists. I'm using a combo of WOF templates, and Skip's Peps. (I know, they're the same.) I'm only doing the helmet now, for it'll take a ton of cash to buy the aluminum. But for the helmet, I found some cheap stuff. Dryer vent aluminum, that's not coiled up for $4. About the size of 2-3 sheets of paper. Assembly is being done with rivets (partially for strength, partially for effect) and epoxy will also help. The alum is really thin, so I want to reinforce it later. Let me know what you think, and please be kind, for it's my first try again. But also feel free to comment away. I want to do my best on this. and without further delay...
The cheekplate is wee bit out of alignment, but bondo should cover it. I'd do more, but out of pop rivets. What you see is actually what I call, "Metalkura" Basicially, I glued pepakura templates to the metal, then cut and folded it. Since mando helms are so curvy, not like Mk.VI spartan armor, it's insanely easy. I'll add WOF pieces on the ears, and back to supplement it. I prefer working in pep (spent too much time around the 405th) so that why I didn't do a straight WOF template build.

Thanks. When I walked into the store, I fully indended to buy plastic... but then, seeing metal... it was almost as reasonable too. Plus, far less chance of the thing breaking. I think the ear pieces though, will be plastic. The metal is having issues bending without cracking.

I should have more pics up this evening (my evening anyway) because I bought more rivets, and I finished the left ear, minus some cleanup. I'm alos thinking of slightly changing the shape of the cheek on the bottom. I want this to be something of a "Mandalorian commando" black scheme with some cool stuff on it. A type of hybrid of an RC and mandalorian.

I would use very thin metal for the dome. I think mine was still too thick. I eventually used JB KWIK and then Bondo to smooth it up. I was still in the process smoothing it when I stopped. I used Goop to glue mine together though... the bond is still real strong too. Anyway... I'll keep looking here to see how you're doing... let me know if I can help. Thanks!